Details

Overview
The CCB Burn Test Rig is a turnkey, fully pneumatic platform designed for comprehensive burn-in and functional testing of Central Control Block (CCB) electronic brake controllers.

By simulating the pressure cycles and electrical loads these controllers experience in real-world rail and automotive braking systems, the rig precipitates early-life failures, validates design robustness, and guarantees long-term reliability before units are released into
service.

Key Features & Capabilities
- Multi-Channel Burn-In: Simultaneously tests up to four CCB controllers, maximizing throughput.
- Precision Pressure Control: High-accuracy regulator delivers 0–16 bar air pressure with Class 0.05 dual-scale gauge (0–16 kg/cm2 | 0–220 PSI).
- Staged Reservoir Array: Eight stainless-steel tanks (two × 25 L, five × 13 L, one customer-provided 13 L) ensure stable pressure between cycles.
- Rapid UUT Hookup: BSP quick-release couplings (11⁄2′′, 1′′, 1⁄2′′, 1⁄4′′) and 3 m braided hoses on reels enable fast changeovers.
- Compact Mobility: All components—filters, valves, gauges, power supply—are mounted on a wheeled extruded-aluminum frame for easy relocation.
- Integrated DC Power: Dual-output 0–120 V DC @ 7 A supply powers controller electronics under test.

Components & Technical Specifications

  

    

      
Component
      
Description
    
  
  

    

      
Air Filter & Regulator
      
1″ line (adaptor to 1½″), 0–12 bar regulator
    
    

      
SS Reservoirs
      
25 L (2) & 13 L (5) rated 10 bar (tested to 16 bar)
    
    

      
Valves (Cocks)
      
1½″, 1″, ½″, ¼″ sizes, 10 bar line pressure
    
    

      
Safety Valves
      
¼″ spring-loaded set at 10 bar
    
    

      
Pressure Gauge
      
Dual-scale 0–16 kg/cm² | 0–220 PSI, LC 0.05, ±0.25% accuracy
    
    

      
Couplings & Nipples
      
BSP-threaded (1″, 3/8″, 1/4″) quick-release couplings & matching nipples
    
    

      
Hoses
      
BSP female swivel 1½″, 1″, ½″, ¼″; 3–4 m length; 10 bar rated
    
    

      
Calibration Port
      
¼″ Minimess coupling for external calibration
    
    

      
Control Panel & Frame
      
Extruded-aluminum with four wheels; custom layout for regulator, gauges, hose reels
    
    

      
DC Power Supply
      
Dual-output 0–120 V DC, 7 A
    
  


Operational Guidelines
Do’s
- Keep hoses, reservoirs, and fittings clean and debris-free.
- Confirm inlet air supply integrity and zero leaks before pressurization.
- Adhere to the prescribed test sequence and timing.
- Verify correct valve positions (open/closed) per test setup.
- Monitor gauges and digital indicators throughout testing.

Don’ts
- Never disconnect hoses under pressure.
- Do not perform maintenance until the system is fully vented.
- Avoid introducing contaminants into air lines or tubing.
- Do not operate with loose or damaged connections.

Maintenance & Calibration Schedule

  

    

      
Interval
      
Actions
    
  
  

    

      
Before/After Each Use
      
Visual inspection; confirm gauges read zero; check for leaks.
    
    

      
Monthly
      
Leak check tubing/piping; clean exterior; verify filter/regulator performance.
    
    

      
Every 3 Months
      
Inspect inlet line; clean filter element; torque-check all fittings.
    
    

      
Every 6–12 Months
      
Full-pressure leak test; calibrate/replace gauges and transmitters; replace pneumatic components; in-situ relief valve checks.
    
    

      
Every 5 Years
      
Overhaul major assemblies—flow meters, relief valves, regulators; replace piping as needed.
    
  


Safety & Compliance
High-Pressure Precautions: Only qualified personnel; follow LOTO and high-pressure safety protocols.
Certified Components: All gauges supplied with traceable calibration certificates; complies with EN 50155, IEC 61373 and other relevant standards.
Documentation Package: Comprehensive operation, troubleshooting, and maintenance manuals included.

Applications
The rig seamlessly integrates into OEM production lines for 100% burn-in and design verification, and into Tier-1 supplier quality-assurance workflows for batch testing and incoming inspection. Railway operators and depots use it for in-service health checks,
refurbishment validation, and predictive maintenance. Independent labs leverage its multiunit capacity and data-logging for contract and standards-compliance testing, while R&D teams combine it with environmental chambers for advanced thermo-pneumatic stress screening and manufacturing process optimization.

Conclusion
By combining precise pneumatic control, robust modular design, and industry-proven burnin methodologies, the CCB Burn Test Rig delivers unparalleled reliability validation for brake controller electronics. It uncovers latent defects, enforces stringent safety standards,
and drives continuous quality improvements—ensuring

      

English
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Russian
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